Plasticiser-free TPE sealants on growth course

When commercial production commenced in early 2011, it was possible to generate interest on a broad scale. Almost all of the leading brand names in the area of food containing fat/oil have started testing lids with the PVC-free closure sealing compound, says Actega DS. The majority of baby food manufacturers are prepared to change to this PVC-free alternative as soon as this variant is available in the Provalin family, says the company.

Developed with the aim of replacing PVC with PVC-free sealing materials complying with FDA and EU guidelines and guaranteeing the highest level of food safety, Provalin displays additional advantages along the value-added chain from production through usage to recycling apart from maintaining the toughest migration limits even in the smallest packaging, longer storage periods or under unfavourable conditions, according to the company. Thanks to the TPE technology used, for example, significantly less energy and space are required as the curing ovens are no longer a necessity (the PVC-free granulate is applied and formed in the lid but no longer requires curing or gelling). Carbon dioxide emissions can be reduced while applications involving granulate are cleaner and result in lower volumes of waste. Storage stability is neither influenced nor limited and there are no viscosity problems unlike in the case of PVC plastisols. Ultimately, less sealing material is required without any negative impact on performance. Also liquid plasticisers are not required for the flexibility/elasticity of PVC, TPE granulate minimises the potential causes of migration by undesirable substances. Additionally the TPE material is recyclable (no problems associated with incineration).

In 2008, it was possible to extensively test and present Provalin 1241 as a comprehensive sealing compound for products with a high oil/fat content in Twist-Off caps. Ring technology has been applied since 2009 and examined ever since. On the basis of these findings, additional variants of the Provalin family have been developed: 1231, suitable for pasteurisation, sterilisation and products containing little or no oil; 1631, for contents such as 1231 but in the area of composite caps; 1288, as a full solution for products with or without a high oil/fat content, suitable for both pasteurisation and sterilisation. A version for P/T caps is currently under development.

Provalin 1241 meanwhile exceeded all expectations of long-term studies over 24 months in regards to storage safety, vacuum retention, opening characteristics and migration, says Actega DS. Sales to German clients are currently being successively extended – from TO 66 mm since early 2011 to TO 53 and 63 mm as of mid-2011, TO 48, 58 and 70 mm as of Q3 2011 and TO 51 and 82 mm to the end of the year.

Long-term studies and production tests are also available for Provalin 1231 while tests on commercial production lots have been ongoing since Q2. Provalin 1631 has been used in the Bandguard closures in Southeast Asia in particular since 2006. Annual production: approximately 500 million pieces.

Provalin 1288 has been undergoing testing for the past six months. Very good results can be recorded both in terms of vacuum and migration from cold and hot contents so there is nothing to stop commercialisation as of Q4., says Actega DS.

A variant for the stringent specifications governing baby food is currently undergoing very intensive laboratory testing. Here as well, the initial results achieved have been very positive. The intention is to have this compound available for commercialisation during 2012, says the company.